Head tool changer for use with deposition-based digital manufacturing systems

Abstract

A head tool changer for use with a deposition-based digital manufacturing system, the head tool changer comprising a tooling unit configured to retain a deposition head, a grip unit configured to engage with tooling unit and to relay electrical power to the tooling unit, and a master unit operably mounted to a gantry and configured to engage with the tooling unit and to relay electrical power to the tooling unit.

The invention claimed is: 
     
       1. A method for building a three-dimensional model with a deposition-based digital manufacturing system, the method comprising:
 engaging a tooling unit with a tool rest assembly, wherein the tooling unit retains a deposition head; 
 relaying electrical power through the tool rest assembly and the tooling unit to the retained deposition head while the tooling unit is engaged with the tool rest assembly; 
 disengaging the tooling unit from the tool rest assembly; 
 moving the tool rest assembly away from the tooling unit; 
 engaging the tooling unit with a master unit that is operably mounted to a gantry of the deposition-based digital manufacturing system; 
 relaying electrical power through the master unit and the tooling unit to the retained deposition head while the tooling unit is engaged with the master unit; 
 moving the master unit and the retained deposition head with the gantry; 
 feeding a consumable material through the retained deposition head with the electrical power relayed through the master unit and the tooling unit; and 
 depositing the fed consumable material from the retained deposition head while moving the master unit to build at least a portion of the three-dimensional model using a layer-based additive technique. 
 
     
     
       2. The method of  claim 1 , wherein the deposition-based digital manufacturing system comprises a controller, and wherein the method further comprises relaying control signals from the controller through the master unit and the tooling unit to the retained deposition head while the tooling unit is engaged with the master unit. 
     
     
       3. The method of  claim 1 , wherein the tool rest assembly comprises a turret configured to retain a plurality of deposition heads. 
     
     
       4. The method of  claim 1 , and further comprising heating up the deposition head with the electrical power relayed through the tool rest assembly and the tooling unit. 
     
     
       5. The method of  claim 1 , and further comprising:
 engaging the tooling unit with a grip unit operably connected to an actuator assembly; 
 disengaging the tooling unit from the tool rest assembly; and 
 moving the actuator assembly to position the tooling unit proximate to the master unit. 
 
     
     
       6. The method of  claim 1 , and further comprising:
 drawing a vacuum through a purge receptacle; and 
 purging the deposition head into the purge receptacle. 
 
     
     
       7. The method of  claim 1 , and further comprising:
 disengaging the tooling unit from the master unit; 
 re-engaging the tooling unit with the tool rest assembly; and 
 relaying electrical power through the tool rest assembly and the re-engaged tooling unit to the retained deposition head while the tooling unit is re-engaged with the tool rest assembly. 
 
     
     
       8. The method of  claim 7 , wherein the tooling unit is a first tooling unit and the deposition head is a first deposition head, and wherein the method further comprises:
 engaging a second tooling unit with the tool rest assembly, wherein the second tooling unit retains a second deposition head; 
 relaying electrical power through the tool rest assembly and the second tooling unit to the retained second deposition head while the second tooling unit is engaged with the tool rest assembly; 
 after disengaging the first tooling unit from the master unit, engaging the second tooling unit with the master unit; and 
 relaying electrical power through the master unit and the second tooling unit to the retained second deposition head while the second tooling unit is engaged with the master unit. 
 
     
     
       9. The method of  claim 1 , wherein the deposition head comprises a single extrusion line. 
     
     
       10. A method for building a three-dimensional model with a deposition-based digital manufacturing system, the method comprising:
 providing a tooling unit having a first electrical contact, a second electrical contact, a first locking mechanism, and a second locking mechanism, and which retains a deposition head; 
 engaging the first electrical contact and the first locking mechanism of the tooling unit to a tool rest assembly; 
 relaying electrical power through the tool rest assembly, the first electrical contact and the tooling unit to the retained deposition head while the tooling unit is engaged with the tool rest assembly; 
 engaging the second electrical contact and the second locking mechanism of the tooling unit with a grip unit operably mounted to an actuator assembly; 
 relaying electrical power through the grip unit, the second electrical contract, and the tooling unit to the retained deposition head while the tooling unit is engaged with the grip unit; and 
 loading the retained deposition head into position on a gantry of the deposition-based digital manufacturing system using the actuator assembly for building at least a portion of the three-dimensional model using a layer-based additive technique. 
 
     
     
       11. The method of  claim 10 , wherein the deposition-based digital manufacturing system comprises a controller, and wherein the method further comprises relaying control signals from the controller through the grip unit and the tooling unit to the retained deposition head while the tooling unit is engaged with the grip unit. 
     
     
       12. The method of  claim 10 , and further comprising heating up the deposition head with the electrical power relayed through the tool rest assembly and the tooling unit. 
     
     
       13. The method of  claim 10 , and further comprising:
 moving the tooling unit with the retained deposition head back to the tool rest assembly at least in part with the actuator assembly; 
 re-engaging the tooling unit with the tool rest assembly; 
 disengaging the tooling unit from the grip unit, and 
 relaying electrical power through the tool rest assembly and the re-engaged tooling unit to the retained deposition head while the tooling unit is re-engaged with the tool rest assembly. 
 
     
     
       14. The method of  claim 10 , and further comprising:
 drawing a vacuum through a purge receptacle; and 
 purging the deposition head into the purge receptacle. 
 
     
     
       15. A method for building a three-dimensional model with a deposition-based digital manufacturing system, the method comprising:
 engaging a tooling unit with a tool rest assembly, wherein the tooling unit retains a deposition head; 
 relaying electrical power through the tool rest assembly and the tooling unit to the retained deposition head while the tooling unit is engaged with the tool rest assembly; 
 engaging the tooling unit with a grip unit operably mounted to an actuator assembly; 
 disengaging the tooling unit from the tool rest assembly after engaging the grip unit; 
 moving the tool rest assembly away from the actuator assembly; 
 engaging the tooling unit with a master unit that is operably mounted to a gantry of the deposition-based digital manufacturing system; 
 relaying electrical power through the master unit and the tooling unit to the retained deposition head while the tooling unit is engaged with the master unit; 
 disengaging the tooling unit from the grip unit after engaging the master unit; and 
 building at least a portion of the three-dimensional model using a layer-based additive technique with the deposition head while the tooling unit is engaged with the master unit. 
 
     
     
       16. The method of  claim 15 , wherein the deposition-based digital manufacturing system comprises a controller, and wherein the method further comprises relaying control signals from the controller through the master unit and the tooling unit to the retained deposition head while the tooling unit is engaged with the master unit. 
     
     
       17. The method of  claim 15 , wherein the tool rest assembly comprises a turret configured to retain a plurality of deposition heads. 
     
     
       18. The method of  claim 15 , and further comprising heating up the deposition head with the electrical power relayed through the tool rest assembly and the tooling unit. 
     
     
       19. The method of  claim 15 , and further comprising:
 re-engaging the grip unit with the tooling unit; 
 disengaging the tooling unit from the master unit after engaging the grip unit; 
 moving the tooling unit with the retained deposition head back to the tool rest assembly at least in part with the actuator assembly; 
 re-engaging the tooling unit with the tool rest assembly; and 
 disengaging the tooling unit from the grip unit. 
 
     
     
       20. The method of  claim 15 , and further comprising:
 drawing a vacuum through a purge receptacle; and 
 purging the deposition head into the purge receptacle.